-From prototypes to large-scale production, PCB assembly helps turn concepts into functional products that meet industry demands.
But with so many details to manage—design files, components, and timelines—it’s easy to commit errors that lead to added costs and performance issues.
(KamranAydinov/Freepik)
When you enlist PCB assembly services, you want everything to go smoothly. Here are some mistakes to avoid when you outsource a PCB assembly job.
1. Rushing the CM Decision
Choosing the right contract manufacturer (CM) is critical. It’s easy to rush into a decision, but don’t.
You need to evaluate different options, check certifications, and understand the CM’s capabilities. Take the time to visit their facility, ask questions, and ensure they align with your product needs.
2. Not Considering Component Availability
Before jumping into your PCB assembly order, always double-check that all the parts you need are actually available. Some components might have long lead times or, worse, might be discontinued altogether. This can crunch your timeline. If you need a part that’s hard to find or might be out of stock, check with your contract manufacturer (CM) early.
A heads-up from the CM can help you find alternative parts or avoid surprises later. They can usually recommend substitutes or work with you to adjust the design so everything’s in stock and ready to go.
3. Sending Incompatible Design Files
If you’re not careful with your design output files, you risk confusion and delays. There are different file formats like Gerber, IPC 2581, ODB++, and BoM files that need to be sent in the formats your PCB assembly company accepts.
Make sure the design files you submit match the specific requirements for your CM. Double-check that your BoM and X-Y placement files are in the correct format to avoid back-and-forth communication.
4. Sending Vague Instructions
Clear assembly instructions are key. When you don’t provide specific mounting sequences, component orientations, or testing procedures, it makes life harder for your CM.
For instance, if your design uses sensitive EMI components, make sure the assembly instructions include details about shielding and handling procedures.
5. Skipping Design for Manufacturability (DFM) Review
Skipping a DFM review seems like a shortcut, but it will cost you down the road.
Make sure your PCB design meets the manufacturer’s capabilities and standards. Review your design with the contract manufacturer before finalizing the order. A DFM review ensures that your design is manufacturable and will result in fewer assembly errors, lower costs, and a smoother process overall.
6. Underestimating Lead Times
It’s easy to get excited and promise quick delivery times, but underestimating lead times can cause big problems.
Take the time to discuss realistic timelines with your contract manufacturer and factor in buffer time for any unexpected delays. Be honest with your team or stakeholders about the timeline so you don’t risk letting them down or compromising quality in a rush to meet a deadline.
7. Neglecting Compliance and Certification Requirements
Certain industries—such as medical, aerospace, or automotive—have strict regulations and certifications for their PCBs. If you don’t pay attention to these requirements upfront, it can result in trouble down the road.
Make sure your contract manufacturer is familiar with the necessary standards like RoHS, ISO 13485, or UL certification and can guarantee compliance. Otherwise, you may face delays, fines, or even a product recall.
8. Always Going for the Cheapest Option
It’s tempting to pick the lowest-cost option for PCB assembly, but cheap doesn’t always mean better. Cutting corners on cost can lead to poor-quality parts or assembly issues, and you may end up paying more in the long run to fix those problems.
When you’re choosing a CM, don’t just go for the cheapest quote. Look at their experience, reputation, and the quality of their work. The goal is to find a balance—good quality at a fair price.
9. Not Accounting for Add-on Assembly Costs
Don’t assume the quote is all-inclusive. Many PCB assembly companies offer low initial quotes that can skyrocket once you factor in additional costs like soldering, rework, or special component handling. You might also incur extra fees for services like testing, packaging, and shipping.
Ask your CM to break down the full costs upfront. Understand every potential fee before you sign the contract so you’re not blindsided by hidden costs later. You want a clear view of the final price and how each cost impacts your budget.
10. Not Testing the Assembly Before Full Production
It’s essential to test your PCB assembly thoroughly before diving into large-scale production. Even if your design looks good on paper, there may be small issues that only appear once the components are assembled.
Running a small batch production or a pre-production run can help you catch those issues early. These tests allow you to identify any assembly errors or design flaws before committing to a full order.
11. Overlooking Post-Assembly Support
When you place a PCB assembly order, it’s easy to forget that the job doesn’t end when the board leaves the facility. There’s still post-assembly support to consider—things like repairs, component replacements, and troubleshooting.
Make sure your contract manufacturer offers clear post-assembly support and outlines how they’ll handle any issues after delivery. Knowing this upfront helps you avoid headaches and unexpected costs later on.
Conclusion
Watch out for these mistakes when placing a printed circuit board assembly order. Remember, rushing through the details can lead to setbacks later on.
Take the time to double-check your files, communicate clearly with your contract manufacturer, and make sure everything aligns with your needs. With that, you should be able to avoid costly mistakes and ensure a smooth process from start to finish.
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Infographic
PCB assembly turns concepts into functional products, from prototypes to large-scale production. However, managing details like design files, components, and timelines can lead to costly mistakes. To ensure a smooth outsourcing process, explore this infographic on common errors to avoid in PCB assembly projects.
